Coolant Reservoir: Service and Repair

Surge Tank Replacement

Removal Procedure
1. Drain the cooling system.





2. Remove the surge tank nuts.
3. Loosen the surge tank side nut.
4. Reposition the surge tank inlet hose (1) clamp.
5. Remove the surge tank inlet (1) hose from the surge tank.
6. Reposition the surge tank outlet hose (2) clamp.
7. Remove the surge tank outlet hose (2).





8. Reposition the heater outlet hose clamp from the surge tank.
9. Remove the heater outlet hose from the surge tank.
10. Remove the surge tank.

Installation Procedure

Important: Lubricate the inside diameters of the hoses with clean coolant prior to installation.





1. Install the surge tank.
2. Install the heater outlet hose to the surge tank.
3. Reposition the heater outlet hose clamp to the surge tank.





4. Install the surge tank inlet (1) hose to the surge tank.
5. Reposition the surge tank inlet hose clamp.
6. Install the surge tank outlet hose to the surge tank.
7. Reposition the surge tank outlet hose clamp (2) to the surge tank.

Important: When installing the surge tank ensure that the front stud is fully seated in the slot.





8. Install the surge tank onto the studs.

Notice: Refer to Fastener Notice in Service Precautions.

9. Install the surge tank upper nuts.
10. Tighten the nuts in the following sequence:
10.1. Bottom
10.2. Top rear
10.3. Top front
Tighten the radiator surge tank nuts to 10 Nm (89 inch lbs.).
11. Fill the cooling system.